Modular construction with dedicated module water drainage system

ABSTRACT

A module for a modular construction having a plurality of pre-fabricated panels including a façade panel, a rear panel, opposing side wall panels, a floor, and a ceiling. The drainage system for each module includes a gabled roof which supports a drainpipe for the module. Each roof portion has a slope in the range of approximately 0.1% to 5.0%. Opposing side panels have an extended height so as to provide a footed base to the module when assembled wherein the footed base provides a space below the floor of the module. A plurality of modules are assembled and connected to vertically and horizontally adjacent modules to form a modular construction. The drainage system for each module and the modular construction direct the drainage at angle away from the interior of the module and construction and out through the façade.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and the benefit of U.S. provisional application Ser. No. 62/958,602, filed on Jan. 8, 2020, the content of which is hereby incorporated in its entirety.

BACKGROUND

The present invention relates to modular constructions. More specifically, the invention relates to a module for modular constructions where each module has a dedicated drainage system.

During construction, modular constructions include modules that once assembled are exposed to the elements, allowing rain or snow fall to accumulate on or in the modular construction.

SUMMARY

An aspect of the present disclosure relates to a modular construction comprising a plurality of modules. Each module comprises four vertical walls, a floor, a base, a gabled roof, and a drainage system.

The gabled roof has a slope in the range of approximately 0.1% to 5.0%.

The base comprises legs which raise the floor of the module such that a first module may be stacked on top of a second module of the plurality of modules with sufficient room for the gabled roof of the first module to be positioned below the floor of the second module.

The drainage system comprises at least one drainpipe. Each module may support a drainpipe on each side of the module. The drainpipe is supported on the roof of the module or on roofs of horizontally adjacent modules. The drainpipe is angled towards a façade of the module.

The drainpipe is positioned at a slope in the range of approximately 0.1% to 2.0% to direct drainage away from an assembled module.

One of the vertical walls comprises a façade on an outer face.

The drainage system also may comprise a moisture sensor. The module further comprises a waterproof membrane on or over at least a portion of the gabled roof.

The plurality of modules comprises at least two horizontally adjacent modules and at least two vertically stacked modules. The adjacent and stacked modules are removably secured together via one or more connectors.

Another aspect of the present disclosure relates to a module for a modular construction. The module comprises a plurality of pre-fabricated panels including a façade panel, a rear panel, opposing side wall panels, a floor, and a ceiling. The module also comprises a gabled roof for supporting a drainpipe for the module wherein each roof portion has a slope in the range of approximately 0.1% to 5.0%. The opposing side panels have an extended height so as to provide a footed base to the module when assembled wherein the footed base provides a space below the floor of the module.

Terminal side ends of the gabled roof are configured to support a side edge of a drainpipe thereon.

The roof portions are each gabled in the direction of the side panels such that the drainpipe is positioned at an angle for drainage towards the façade panel and away from an assembled module.

The drainpipe has an incline in the range of approximately 0.1% to 2.0% to direct drainage towards the façade panel and away from an assembled module.

The module further comprising a waterproofing membrane on at least a portion of the gabled roof.

The module is configured for vertical and horizontal connection with subsequent modules. The module and subsequent modules are stackable and the footed portion of an upper module is secured on top of terminal side ends of the gabled roof such that there is an airgap between the gabled roof of a lower module and the floor of an upper module. At least one drainpipe is supported between the footed portion of the upper module and the terminal side end of the lower module on at least one side of the modules.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a modular construction with drainage system according to the present disclosure.

FIG. 2 is a front perspective view of two adjacent modules in the modular construction with drainage system according to the present disclosure.

FIG. 3 is an additional perspective view of a module.

FIG. 4 is a top view of one embodiment of each row of modules in the modular construction.

FIG. 5 is a front view of the modular construction.

FIG. 6 is a side view of two vertically adjacent, or stacked, modules of the modular construction.

FIG. 7 is a front view of a drainpipe for a module in the modular construction.

FIG. 8 is a side view of the drainpipe for the module in the modular construction.

FIG. 9 is a top view of the drainpipe for the module in the modular construction.

FIG. 10 is a front view of one embodiment of modules in the modular construction.

FIG. 11 is a front view of another embodiment of modules in the modular construction.

FIG. 12 is a front view of another embodiment of modules in the modular construction.

FIG. 13 is a front view of another embodiment of a module for the modular construction.

DETAILED DESCRIPTION

A module for use in a modular construction is described herein. Each module is configured for use in modular constructions such that a plurality of modules may be assembled and connected to one another, horizontally and vertically, to form the modular construction. The modules may be connected in rows and stacked to form two, three, four or more levels to the modular construction. Each module is provided with a corresponding water drainage system that is in addition to a drainage system for the overall modular construction. Adjacent units are securely connected to one another when constructing the modular construction via connecting mechanisms that allow secure connection of adjacent vertical and horizontal modules in a removable manner such that the modular construction can be dis-assembled, moved, and re-assembled on-site as needed.

The modular construction comprises a plurality of similarly constructed modules each having its own drainage system which can be useful during construction of the module as well as during construction of the modular construction. The drainage system for each module can also be beneficial once the modular construction is constructed to prevent water issues in one module from damaging or affecting an adjacent or lower module.

Once constructed, the modules are further protected from accidents in adjacent or upper modules for example, as leaking or broken water pipes may leak but the dedicated drainage system of the modules including the joints between adjacent modules serves to directed water away from the modules to the façade or exterior of the modular construction where the water is then drained from the modular construction. It is further contemplated that the modules may also accommodate a moisture or water sensor in or adjacent to the drainage system and/or joints between modules to detect water after the modular construction is completed which can indicate there is a leak within the modular construction for leak reporting.

In the embodiment illustrated in FIGS. 1-13, the modular construction 10 comprises a plurality of modules 12. Each module 12 comprises four vertical walls 14, 16, 18, and 20 including a front wall 14 having a façade 15 and a back wall 16 with two opposing side walls 18 and 20 which form the module 12. Each module further comprises a base 22 and a roof 24. As illustrated in the figures, each of the side walls 18 and 20 have a height greater than a height of the front wall 14 and back wall 16 such that when the module 12 is assembled, a bottom length 26 of the side walls 18 and 20 extends downwardly to provide the base 22 to the module 12 with a support such as feet 28. The base 22 allows a floor of the module 12 to be raised. The side walls 18 and 20 may also each have a length greater than a length of the front and back wall such that when the module 12 is assembled, the module 12 may have an overall rectangular shape. However, various lengths and heights of the walls may be used to form a module 12 of selectable dimensions. Ideally the modules are all of the same dimensions. However, in certain situations the modules may differ in dimensions.

Each module 12 may also comprise a pre-fabricated façade panel 15 for attaching to an outer face of the module 12 and in one embodiment the façade panel 12 may be provided already attached to the outer face of the module 12. An upper portion of each module 12 supports the drainage system 30 which allows for the collection and draining of water out of the modular construction including through the façade 15 during construction of the module 12 and the assembly of the modular construction 10 as well as during the lifetime of the assembled modular construction 10. The drainage system 30 of each module 12 provides secondary protection to the module 12 in the event of the presence of water or water leaks. A humidity sensor and/or moisture sensor (not illustrated) may be placed near the drainage exit.

The modules 12 are stackable by way of the base 22 being configured to accommodate a roof 14 of a second module 12 b when the second module 12 b is secured on top of a first module 12 a as illustrated in FIG. 3. While the extended length of the side walls 18 and 22 provides feet 28 to the base 22, feet or other supports may be provided to the base 22 integrally or otherwise secured thereto to raise the floor of the module 12 when the module 12 is assembled. This provides an open space 34 below the floor of the assembled module 12 extending between the feet. Airgaps 46 are also provided between adjacent horizontal modules 12 in the modular construction 10.

The roof 24 may be gabled as illustrated in FIGS. 1-6, for example and thus comprise two roof sections 25 and 26 sloping in opposite directions and placed such that the highest edges meet to form the roof ridge. Additional or alternative roof 24 configurations are illustrated in FIGS. 10-13 and are discussed in detail further below. Referring to the embodiment of FIGS. 1-6, each roof section 25 and 26 may have a same or different slope. Each roof section 25 and 26 may have a slope in the range of about approximately 0.1% to about 5.0% in the direction of arrows 13, and may for example be directed towards long, or side walls 18 and 20, of the module 12. As illustrated in FIG. 3, the roof sections may be oriented toward other walls. The roof 24 may further be provided with a waterproof covering or coating. When stacked, the gabled portion of a lower module 12 b, 12 d, 12 f is provided within the open space 34 below the floor of the module 12 a, 12 c, 12 e positioned thereon. An air gap is also present such that the roof 24 does not contact an underside of the floor.

Each roof section 25 and 26 slopes down to connection with the corresponding side wall 18 and 20. Where the roof section 25 and 26 connects to the corresponding side walls 18 and 20, there may be a flat or substantially horizontal portion 40 extending along the length of the roof 24 coextending with the length 26 of the side walls 18 and 20. This flat or substantially horizontal portion 40 is a support for positioning the base 22 of a second module 12 a, 12 c, 12 e, on top of a first module 12 b, 12 d, 12 f.

Referring to FIGS. 10-13, the roof 24 may be one of various configurations and remain compatible with the modular construction as described herein. As illustrated in FIG. 10, the roof 24 is a single section 126 with a convex or other arcuate shape such that opposing sides of the section 126 are sloped in opposite directions and a center portion of the single section 126 is elevated above both opposing ends of the section 126. The roof 24 connects with the side walls 18 and 20 in substantially the same manner as described previously and further herein.

Illustrated in FIG. 11 is roof 24 also comprising a single sheet 226 where the sheet 226 is sloped from connection with one side wall 18 to the opposing side wall 20. The slope again may be in the range of approximately 0.1% to 5.0% As also shown in FIG. 11, two adjacent modules may have mirror image orientation of the sheet 226 such that each roof 24 slopes down to a drain mechanism between the modules 12.

Illustrated in FIG. 12 is the roof 24 also comprising the single sheet 226 where the sheet 226 is sloped from connection with one side wall 18 to the opposing side wall 20. The slope again may be in the range of approximately 0.1% to 5.0%. However, two adjacent modules may have the same orientation of the sheet 226 such that each roof 24 slopes down in the same direction and two adjacent modules 12 are connected low end to high end. The orientation of modules in FIG. 12 may be combined with the orientation of additional modules according to FIG. 11 when providing a larger module construction with a plurality of modules 12.

Referring next to FIG. 13, the roof 24 may be a gabled roof with three sections (or a single sheet having three portions) 325, 326, 327 where section 327 is a center section that may have a slope of zero or substantially zero which provides a flat length to a center of the roof 24. The opposing side sections 325 and 326 then may each have a slope in the range of approximately 0.1% to 5.0% and sloping downwardly from the center section 327 towards connection with the respective sidewall 18, 20.

Referring back to FIGS. 7-9, the roof 24 further supports a drainpipe 44 of the drainage system 30. That is, each module 12 includes a dedicated drainage system 30 comprising a drainpipe 44 supported on or by the roof 24 of the module and the roof 24 of the adjacent horizontal module 12.

The drainpipe 44 itself or its positioning within the joints between adjacent modules may also be shaped with a slope in the range of about approximately 0.1 to about 2.0% in the direction of arrow 45 and/or directed towards the façade portion 15, or front, of the modular construction 10 to drain water away from the module 10 and outside of the modular construction 10. The roofs 24 and/or joints may also be provided with a waterproof covering or coating. The waterproof material may be further connected to the waterproof material of the roof with a seal therebetween.

When constructing or assembling the modular construction 10 the modules within the construction can be exposed to the elements and the dedicated drainage 30 and waterproofing system for each module 12 allows rain or snow for example to be directed toward the joints between adjacent modules 12 where drainage systems direct the water away from an interior of the modular construction 10 and towards the façade 15 or exterior of the modular construction where the water can then be drained away from the modular construction 10.

In one embodiment, the modules 12 may be constructed from prefabricated and/or substantially flat elements including walls and interior elements including floors and ceilings. The walls may comprise prefabricated elements including a steel frame and/or wooden frame and/or standard concrete with metallic reinforcement components and/or non-metallic reinforcement components.

The interior ceiling of the module 12 may be comprised of a prefabricated slab of light weight structure such as a wooden or lightweight steel material and may comprise a gypsum or wooden board cladding.

The floor of the module 12 may be a slab formed by in situ casting of standard concrete, or precast concrete, a reinforced slab also with non-metallic reinforcement, or an in situ casted or precast composite slab comprising a trapezoidal metal sheet, concrete, and standard and non-metallic reinforcement.

Each module is configured for on-site assembly, disassembly and re-assembly without limit. For example, the modular construction can be assembled on-site, used, disassembled, moved and reassembled at will.

Although the present disclosure has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the disclosure. 

1. A modular construction comprising: a plurality of modules, wherein each module comprises: four vertical walls; a floor; a base; a sloped roof; and a drainage system.
 2. The modular construction of claim 1 wherein the sloped roof is a gabled roof and has a slope in the range of approximately 0.1% to 5.0%.
 3. The modular construction of claim 1 wherein the base comprises legs which raise the floor of the module such that a first module may be stacked on top of a second module of the plurality of modules with sufficient room for the sloped roof of the first module to be positioned below the floor of the second module.
 4. The modular construction of claim 1 wherein the drainage system comprises a drainpipe.
 5. The modular construction of claim 4, wherein the drainpipe is positioned at a slope in the range of approximately 0.1% to 2.0%.
 6. The modular construction of claim 4, wherein the drainpipe is supported on the roof of the module.
 7. The modular construction of claim 6, wherein the drainpipe is supported on the roofs of adjacent modules.
 8. The modular construction of claim 6, wherein the drainpipe is angled towards a façade of the module.
 9. The modular construction of claim 1, wherein one of the vertical walls comprises a façade on an outer face.
 10. The modular construction of claim 1, wherein the drainage system comprises a moisture sensor.
 11. The modular construction of claim 1, wherein the module further comprises a waterproof membrane on or over at least a portion of the sloped roof.
 12. The modular construction of claim 1, wherein the plurality of modules comprises at least two horizontally adjacent modules and at least two vertically stacked modules.
 13. The modular construction of claim 12, wherein the adjacent and stacked modules are removably secured together via one or more connectors.
 14. A module for a modular construction comprising: a plurality of pre-fabricated panels including a façade panel, a rear panel, opposing side wall panels, a floor, and a ceiling; and a roof for supporting a drainpipe for the module wherein the roof has a slope in the range of approximately 0.1% to 5.0%, and wherein the opposing side panels have an extended lower height so as to provide a footed base to the module when assembled wherein the footed base provides a space below the floor of the module.
 15. The module of claim 14 wherein terminal side ends of the sloped roof are configured to support a side edge of a drainpipe thereon.
 16. The module of claim 15 wherein the roof comprises two portions that are each gabled in the direction of the side panels such that the drainpipe is positioned at an angle for drainage towards the façade panel and away from an assembled module.
 17. The module of claim 15 wherein the drainpipe has an incline in the range of approximately 0.1% to 2.0% to direct drainage towards the façade panel and away from an assembled module.
 18. The module of claim 14 and further comprising a waterproofing membrane on at least a portion of the roof.
 19. The module of claim 15 wherein the module is configured for vertical and horizontal connection with subsequent modules.
 20. The module of claim 19 wherein the modules are stackable and the footed portion of an upper module is secured on top of terminal side ends of the gabled roof such that there is an airgap between the gabled roof of a lower module and the floor of an upper module and wherein at least one drainpipe is supported between the footed portion of the upper module and the terminal side end of the lower module on at least one side of the modules. 